Adam Sharman, CEO LMAC Group, APAC

As manufacturing organisations strive to optimise their operations, the adoption of technology has always been a key focus. In the last 10 years, developments in digital technologies for manufacturers have increased pace and, whilst most organisations recognise the opportunity presented by these developments, the rapidly changing ecosystem of systems can make it difficult to identify the best fit for the business.

The landscape of manufacturing or operational management systems has evolved considerably in recent years, with multiple options available to fit the needs of the business based on scale, complexity and requirements.

Three solutions that have gained significant traction are Manufacturing Execution Systems (MES), Manufacturing Data Hubs (MDH), and Machine Monitoring Platforms (MMP). Each offers unique benefits and comes with its own set of limitations.

This article aims to provide a comprehensive comparison to help manufacturers make informed decisions on which of these solutions is the best fit when considering investment in OT software.

Manufacturing Execution Systems (MES)

MES is a comprehensive software solution that manages and monitors work-in-process on the factory floor. It operates in real time to enable the control of multiple elements of the production process, including:

– Resource allocation and status

– Production scheduling

– Dispatching production units

– Quality management

– Labor and material tracking

– Performance analysis

MES serves as a bridge between planning systems like ERP (Enterprise Resource Planning) and the actual production processes, providing a holistic view of how current conditions on the plant floor can be optimised to improve production output.

Benefits

1. Comprehensive Production Management: MES provides end-to-end visibility and control over production processes, from order release to finished goods.
2. Real-time Decision Making: Offers real-time data and analytics, enabling quick responses to production issues.
3. Quality Control: Integrates quality management processes, reducing defects and improving overall product quality.
4. Resource Optimisation: Helps in optimising the use of materials, labour, and equipment.

Limitations

1. Complex Implementation: MES can be complex to implement, often requiring significant time and resources.
2. Cost: Generally more expensive than other solutions, both in terms of initial investment and ongoing maintenance.
3. Rigidity: Some MES solutions may be less flexible in adapting to rapid changes in manufacturing processes.

Manufacturing Data Hubs (MDH)

A Manufacturing Data Hub (MDH) is a centralised data management system designed to collect, store, and organise data from various sources across the manufacturing environment. It acts as a single source of truth for all manufacturing-related data, including:

– Production data

– Quality data

– Supply chain information

– Machine performance data

– Energy consumption data

MDH focuses on data integration, normalisation, and accessibility, enabling manufacturers to break down data silos and facilitate more comprehensive analytics and reporting.

Manufacturing Data Hubs can provide a virtual centralisation of data across multiple systems, machines and PLCs for the purposes of monitoring and analysis of real-time performance. MDH differ from a data warehouse or data lake where the data is centralised into a physical (not-virtual) centralised data repository.

Benefits

1. Data Centralisation: MDH excels at collecting, storing, and organising data from various sources across the manufacturing environment.
2. Improved Data Accessibility: Provides a single source of truth, making it easier for different departments to access and utilise manufacturing data.
3. Enhanced Analytics: Facilitates advanced analytics and reporting by consolidating data from multiple systems.
4. Scalability: Generally more scalable than MES, allowing for easier integration of new data sources.

Limitations

1. Limited Process Control: Unlike MES, MDH typically doesn’t provide direct control over manufacturing processes.
2. Data Quality Dependence: The effectiveness of MDH relies heavily on the quality and consistency of input data from various sources.
3. Potential for Data Overload: Without proper management, the vast amount of data collected can become overwhelming and difficult to navigate.

Machine Monitoring Platforms (MMP)

Machine Monitoring Platforms (MMP) are specialised systems, focused on collecting and analysing data from manufacturing equipment in real-time. MMP typically include:

– Real-time machine status monitoring

– Production counting and cycle time tracking

– Downtime tracking and analysis

– OEE (Overall Equipment Effectiveness) calculations

– Predictive maintenance alerts

Machine Monitoring Platforms are primarily concerned with machine performance, efficiency, and maintenance, providing deep insights into equipment utilisation and potential issues. MMPs are a good fit where the priority is understanding the production, rather than controlling machines, as in a Supervisory Control and Data Acquisition (SCADA) system.

Benefits

1. Focused Insight: Provides deep, real-time insight into machine performance and status.
2. Predictive Maintenance: Enables predictive maintenance strategies, reducing downtime and maintenance costs.
3. Easy Implementation: Generally easier and quicker to implement compared to comprehensive MES solutions.
4. Cost-Effective: Often more affordable, especially for smaller manufacturers or those focusing primarily on equipment efficiency.

Limitations

1. Limited Scope: Primarily focused on machine performance, lacking the broader production management capabilities of MES and the control capabilities of SCADA.
2. Integration Challenges: May require additional effort to integrate with other manufacturing systems for a holistic view.
3. Data Context: While rich in machine data, MMP may lack the broader context of production processes and business objectives.

Choosing the Right Solution

The choice between MES, MDH, and MMP depends on various factors including the size of the operation, specific industry needs, existing technology infrastructure, and budget constraints.

• Large, Complex Operations: May benefit most from a comprehensive MES solution, despite the higher cost and complexity.
• Data-Driven Organisations: Might find MDH most valuable for its ability to centralise and analyse data from multiple sources.
• Equipment-Centric Manufacturers: Could see significant ROI from an MMP, especially if machine efficiency is a primary concern.

Many manufacturers are also exploring hybrid approaches, combining elements of these solutions to create a tailored system that meets their specific needs. For example, an engineering shop may run an automated line using a machine monitoring platform and an analogue production process that is run with a project management system both of which are reported, scheduled and analysed through an MES.

Conclusion

As manufacturing continues to evolve in the digital age, the choice of technology solutions becomes increasingly critical. Understanding the strengths and limitations of each technology option is crucial in making an informed decision that aligns with manufacturing goals and challenges.

A thorough requirements definition process that captures user information requirements, system and technology integration, flexibility and scalability of the solution, investment required, and industry specificity is critical to identifying the best fit.

Ultimately, the optimal solution will be one that not only meets current needs but also positions the organisation for future growth and adaptation as the industry and market evolves.